IM felt very happy to get a message about the honour to have his blog connected into a global net news organisation for paper industry:
"We have a popular pulp and paper industry news website (http://news.paperindex.com) where we have started covering blogs too. We have posted headline and snippets of your latest blog post on our website. Hope this will help you generate good traffic to your blog."
Microbiology is connected to paper industry in many ways which have been discussed in this blog. There are also microbiologist working on this area worldwide - their number may not be high but their work is very valuable for the use of P&P raw materials, running of the machines, performing QC of paper products as well for the biological waste water treatment.
"Density of paper industry microbiologists" is definitely low in the world but IM hopes that blogging will increase its popularity among P&P microbiologists and he tries himself to inform all readers of www.industrymicrobiologist@blogspot.com about new ideas on this area. He also recommends to visit www.biotouch@blogspot.com which also contains recent news and future forecasts of microbiology and biotechnology.
Saturday, June 7, 2008
Friday, June 6, 2008
Microscopy as an analytical tool for paper industry.
IM (Industrial Microbiologist) has worked as a microscopy teacher and trainer for paper industry since the beginning of 80's. It seems that this analytical tool is very popular: annual courses in Helsinki and at the customers' facilities have indicated an everlasting need to achieve training and experience in microscopy.
There are three major areas of paper industry where microscopy can serve as a rapid tool for analytical control:
There are three major areas of paper industry where microscopy can serve as a rapid tool for analytical control:
- Raw material, process and product microbiology. Traditional Bright Field, Dark Field and Phase Contrast microscopy are always valuable methods. Epifluorescence microscopy techniques (Confocal microscopy included) help significantly when biofilm studies with test coupons will be performed.
- Fibre microscopy. Bright Field microscopy of stained fibre preparates is a common method for the investigations of fibre contents of paper and board.
- Activated sludge microscopy. This is the fastest and most reliable method to check the main activated sludge properties: condition of microbial population and flock formation. It also gives information about sludge age.
Technical equipment for paper industry microscopy bases on ordinary light microscopy, but some prerequisites are needed when microbes are the subject of study:
- illumination technique for "wet preparates" = Phase Contrast illumination.
- higher numerical aperture than for other applications to reach distiction of small objects (an example: N.A. > 1.0 for 40x Phase Contrast objective which means the need of oil immersion - type objectives).
- Epifluorescence (UV) illumination (for trouble shooting and test coupon analyses).
- high-sensitive digital camera (to detect objects in Epifluorescence microscopy).
Laboratory technicians, operators and researchers of paper industry are very interested to apply microscopy into their analytical procedure. These methods, however, need time and patience when learning to explain the views on the preparates. Training is first needed to diagnose all the raw materials of the processes, typical paper industry microbes etc. before a microscopist is ready to solve real trouble shooting samples. The knowledge of different type bacteria, protozoa and higher organisms of activated sludge systems is also needed.
There are two ways to collect experience for the evaluation of microscopical preparates: either training alone with different well-known preparates (tip: slides with bacteria can be bought from certain companies) or join courses where paper industry microscopy will be teach (such kind of courses will be held annually at least in Finland).
Tuesday, May 20, 2008
To be familiar with a paper machine...
Sun has already risen. Taxi leaves Industry Microbiologist (IM) at the mill gate. Wishes of good morning, a short phone call, registration as a visitor...
Then to the mill office. Friendly welcomed by the hosts - usually both from the production and QC laboratories. "Coffee?" - "Thank you, certainly!".
Short conversation about everyday issues. Everybody is sitting down. The meeting can start.
Short presentation of the company, mill, machines and products (if not already known by IM). It is interesting how informative such presentations today are! Basic facts, not too much - room for detailled questions.
Then towards the topics of the day.
There are several types of problems, caused by the microbial activity in raw materials, processes and products. Every problem is individual one and strictly confidential, but references from other mills are relatively easy to find. No more discussion about the problem itself at the moment, but ideas are stored somewhere in the mind.
Process layouts! Excellent! They are really needed to understand this new machine as "fermentor and ecosystem". What kind of raw materials+ What comes from where? Conditions? Flows? Delays in flows? Storage times? Biocide programs? Washing strategies? Several details...
And every time, after the answers - to store all this information somewhere in the mind (of course also on paper). To be processed later in the hotel room with a a pen and a sheet of paper. Different techniques- statistics, time series, even mind mapping...
But, before departure from the mill: visit to the machine. a most important issues. Analytical results from the control room of the machine, discussions with the personnel...Checking CCP's of the wet end and tank section, broke system...
Even more small details to send somewhere, in the back of the head.
Some analytical procedures before leaving. Rapid methods, if possible: luminometry, PC microscopy...
After overnighting, back to the mill. Person at the gate is alredy known by IM. "Hello, I will call...".
Straight to the meeting room. Some new persons have already arrived. Exchange of visit cards (how many different visit cards are there in the world? Is somewhere a museum for visit cards?).
Short summary of yesterdays' experiences and some proposals to be discussed. New persons present new ideas and new points of views. Conclusions, future forecasts.
Collection of small samples (easy to carrry with in IM's car - or to be packaged in a separate bag when flighting). Then the final meeting: what shall be done next? By who?
Farewell wishes, very friendly. Most important dates for activities, meetings, e-mail contacts have already been confirmed.
Leaving the mill - a satisfied feeling: something will progress, some help has been given...
- A typical visit by Industry Microbiologist in a paper mill. He really likes his job!
Then to the mill office. Friendly welcomed by the hosts - usually both from the production and QC laboratories. "Coffee?" - "Thank you, certainly!".
Short conversation about everyday issues. Everybody is sitting down. The meeting can start.
Short presentation of the company, mill, machines and products (if not already known by IM). It is interesting how informative such presentations today are! Basic facts, not too much - room for detailled questions.
Then towards the topics of the day.
There are several types of problems, caused by the microbial activity in raw materials, processes and products. Every problem is individual one and strictly confidential, but references from other mills are relatively easy to find. No more discussion about the problem itself at the moment, but ideas are stored somewhere in the mind.
Process layouts! Excellent! They are really needed to understand this new machine as "fermentor and ecosystem". What kind of raw materials+ What comes from where? Conditions? Flows? Delays in flows? Storage times? Biocide programs? Washing strategies? Several details...
And every time, after the answers - to store all this information somewhere in the mind (of course also on paper). To be processed later in the hotel room with a a pen and a sheet of paper. Different techniques- statistics, time series, even mind mapping...
But, before departure from the mill: visit to the machine. a most important issues. Analytical results from the control room of the machine, discussions with the personnel...Checking CCP's of the wet end and tank section, broke system...
Even more small details to send somewhere, in the back of the head.
Some analytical procedures before leaving. Rapid methods, if possible: luminometry, PC microscopy...
After overnighting, back to the mill. Person at the gate is alredy known by IM. "Hello, I will call...".
Straight to the meeting room. Some new persons have already arrived. Exchange of visit cards (how many different visit cards are there in the world? Is somewhere a museum for visit cards?).
Short summary of yesterdays' experiences and some proposals to be discussed. New persons present new ideas and new points of views. Conclusions, future forecasts.
Collection of small samples (easy to carrry with in IM's car - or to be packaged in a separate bag when flighting). Then the final meeting: what shall be done next? By who?
Farewell wishes, very friendly. Most important dates for activities, meetings, e-mail contacts have already been confirmed.
Leaving the mill - a satisfied feeling: something will progress, some help has been given...
- A typical visit by Industry Microbiologist in a paper mill. He really likes his job!
Monday, May 12, 2008
"Triangle" joint projects / services of paper industry microbiology.
Paper industry microbiology - both research and services - is suffering from the lack of money today (as other research areas, too). Company R&D prefer joint projects instead of their own institutional research. There seems to be certain synergism between partners of paper industry (paper mills, raw material and biocide suppliers as well as research institutes and independent researchers on this area).
A "triangle model" of a joint project has proven to be beneficial one. Alternatives could be
* paper mill + biocide supplier + microbiological services
* raw material supplier + biocide supplier + microbiological services
National funding is very hard to achieve today: a lot of project proposals will be sent every year but a small fraction of them will be accepted by the funding organisations. Direct contacts between partners (mentioned above) in developmental, control and trouble shooting cases are faster and a combination of paper industry experience, knowledge of biocide chemistry and microbiological skills can give the best results in improvement and development of paper machine process and product hygiene.
A "triangle model" of a joint project has proven to be beneficial one. Alternatives could be
* paper mill + biocide supplier + microbiological services
* raw material supplier + biocide supplier + microbiological services
National funding is very hard to achieve today: a lot of project proposals will be sent every year but a small fraction of them will be accepted by the funding organisations. Direct contacts between partners (mentioned above) in developmental, control and trouble shooting cases are faster and a combination of paper industry experience, knowledge of biocide chemistry and microbiological skills can give the best results in improvement and development of paper machine process and product hygiene.
Thursday, March 20, 2008
What is paper industry microbiology?
A combination of paper industry and microbiology is rare.
The last textbook about this topic was published in U.S.A. - the year was something like 1955 (when I was a small boy).
After that, a lot of things have happened. It is a most interesting issue. Have you heard about
* "ecocatastrophe" in process microbiology during the change from acidic to neutral/alcalic process?
* the role of bacteria in this new situation - all environmental conditions in a paper machine have changed?
* the role of calcium carbonate and kaolin in the microbiology of paper machines?
* ever increasing recirculation of process waters give more growth period for selected process bacteria?
* sporulation of bacteria is stimulated by longer recirculation periods - what does it mean?
* biocides may be dosed in TOO LOW levels - in opposite to opinions that all kind of microbiological control of process water automatically lead to lower consumption of biocides?
These are issues which I have dealed with over 20 years. I am therefore asking your opinions!
The last textbook about this topic was published in U.S.A. - the year was something like 1955 (when I was a small boy).
After that, a lot of things have happened. It is a most interesting issue. Have you heard about
* "ecocatastrophe" in process microbiology during the change from acidic to neutral/alcalic process?
* the role of bacteria in this new situation - all environmental conditions in a paper machine have changed?
* the role of calcium carbonate and kaolin in the microbiology of paper machines?
* ever increasing recirculation of process waters give more growth period for selected process bacteria?
* sporulation of bacteria is stimulated by longer recirculation periods - what does it mean?
* biocides may be dosed in TOO LOW levels - in opposite to opinions that all kind of microbiological control of process water automatically lead to lower consumption of biocides?
These are issues which I have dealed with over 20 years. I am therefore asking your opinions!
Tuesday, March 18, 2008
Benefits of microbiological process control - in money?
There are several ways to calculate economical benefits of a proper mb control system. Mind-mapping technique can be used first to detect all aspects included:
TOTAL ECONOMY
An active, problem-preventing microbiological control of raw materials and processes is a most important activity of a paper mill to prevent costs, connected to poor process managements and product faults. We can calculate this value in many ways:
* how much money is spent every second when the production is delayed? 10 euros/s?
* what is the price of a lost jumbo roll, 10...30 metric tons? 5000 € to 30 000 €?
* what are the costs of ineffective / too low / wrongly distributed biocide dosage?
* how much money is spent when a lot of mineral filler or starch is spoiled in a storage tank?
* how much working time of the mill employers is spent for corrective measures after a microbiological problem situation?
* comparison of proper HACCP, based on rapid mb methods and an old-fashioned microbiological control, activated only in hazardous situations?
Different points of view....please think over and refer!
TOTAL ECONOMY
- ECONOMY OF PRODUCTION
- SAVINGS CONNECTED TO SECURED PRODUCT QUALITY
- OTHER ISSUES...?
- COST OF SPOILED RAW MATERIALS
- OPTIMAL BIOCIDE PROGRAMS
- MINIMIZED WASHING & BOILOUT PERIODS
- PREVENTION OF DRIVE DELAYS
- OTHER ISSUES...?
- CUSTOMER CLAIMS....
- FLUENT CONVERTING ACTIONS
- IMAGE OF THE PRODUCT BRAND
- OTHER ISSUES...?
An active, problem-preventing microbiological control of raw materials and processes is a most important activity of a paper mill to prevent costs, connected to poor process managements and product faults. We can calculate this value in many ways:
* how much money is spent every second when the production is delayed? 10 euros/s?
* what is the price of a lost jumbo roll, 10...30 metric tons? 5000 € to 30 000 €?
* what are the costs of ineffective / too low / wrongly distributed biocide dosage?
* how much money is spent when a lot of mineral filler or starch is spoiled in a storage tank?
* how much working time of the mill employers is spent for corrective measures after a microbiological problem situation?
* comparison of proper HACCP, based on rapid mb methods and an old-fashioned microbiological control, activated only in hazardous situations?
Different points of view....please think over and refer!
Monday, March 17, 2008
Rapid control of microbiological status of a paper machine.
Paper industry trust on traditional, proven microbiological methods. Customer claims force the paper mills to use them for end-product QC.
Fast detection - and forecasts - of mb problems cannot be performed by these methods. Some promising progress has taken place since 90's, however:
* optical detection of attachements in paper machine water systems (usually based on IR techniques)
* collection & microscopy of test coupons from processes
* luminometric methods for the evaluation of microbial activity in raw materials and processes
Unfortunately there seems to be no "rapid method" for the estimation of product hygiene yet. Methods of molecular biology may help in future?
Luminometric methods, connected with the examionation of real ("ecologic") process samples is the best alternative for specific assays of microbial counts and activities. Combination of rapid incubation and luminometric assays of process samples is available today ("BIOTOUCH" concept, see figure in right marginal below).
Several calculations and estimations about spare of money has been done. All of them indicate significant reduction of costs which are caused by poor-acting biocide programs (ref. inadequate antibiotic treatment of patients!), problems in machine drive and decreased quality of paper and board product.
Fast detection - and forecasts - of mb problems cannot be performed by these methods. Some promising progress has taken place since 90's, however:
* optical detection of attachements in paper machine water systems (usually based on IR techniques)
* collection & microscopy of test coupons from processes
* luminometric methods for the evaluation of microbial activity in raw materials and processes
Unfortunately there seems to be no "rapid method" for the estimation of product hygiene yet. Methods of molecular biology may help in future?
Luminometric methods, connected with the examionation of real ("ecologic") process samples is the best alternative for specific assays of microbial counts and activities. Combination of rapid incubation and luminometric assays of process samples is available today ("BIOTOUCH" concept, see figure in right marginal below).
Several calculations and estimations about spare of money has been done. All of them indicate significant reduction of costs which are caused by poor-acting biocide programs (ref. inadequate antibiotic treatment of patients!), problems in machine drive and decreased quality of paper and board product.
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